Photovoltaic cell and laminate metallization

Abstract

A photovoltaic laminate is disclosed. Embodiments include placing a first encapsulant on a substantially transparent layer that includes a front side of a photovoltaic laminate. Embodiments also include placing a first solar cell on the first encapsulant. Embodiments include placing a metal foil on the first solar cell, where the metal foil uniformly contacts a back side of the first solar cell. Embodiments include forming a metal bond that couples the metal foil to the first solar cell. In some embodiments, forming the metal bond includes forming a metal contact region using a laser source, wherein the formed metal contact region electrically couples the metal foil to the first solar cell. Embodiments can also include placing a backing material on the metal foil. Embodiments can further include forming a back layer on the backing material layer and curing the substantially transparent layer, first encapsulant, first solar cell, metal foil, backing material and back layer to form a photovoltaic laminate.

What is claimed is: 
     
       1. A method for metallization for a photovoltaic laminate, the method comprising:
 placing a first encapsulant on a substantially transparent layer; 
 placing a first solar cell on the first encapsulant; 
 placing a metal foil on the first solar cell, wherein a first surface of the metal foil uniformly contacts the first solar cell; 
 forming a metal bond that couples the metal foil to the first solar cell; and 
 after forming the metal bond that couples the metal foil to the first solar cell, placing another layer directly on a second surface of the metal foil. 
 
     
     
       2. The method of  claim 1  wherein the other layer comprises a backing material, and the method further comprises:
 placing the backing material on the second surface of the metal foil; 
 forming a back layer on the backing material; and 
 bonding the substantially transparent layer, the first encapsulant, the first solar cell, the metal foil, the backing material and the back layer to form a photovoltaic laminate. 
 
     
     
       3. The method of  claim 1 , further comprising placing a second solar cell on the first encapsulant. 
     
     
       4. The method of  claim 3 , further comprising before placing the first solar cell on the first encapsulant, sorting a plurality of solar cells, wherein placing the first and second solar cells is performed according to the sorting. 
     
     
       5. The method of  claim 1 , wherein forming the metal bond includes forming a metal contact region using a laser source, wherein the formed metal contact region electrically couples the metal foil to the first solar cell. 
     
     
       6. The method of  claim 1 , wherein forming the metal bond comprises:
 performing a patterning process resulting in a patterned metal foil and an excess metal foil; 
 forming the metal bond that couples the patterned metal foil to the first solar cell; and 
 removing the excess metal foil. 
 
     
     
       7. The method of  claim 1 , wherein forming the metal bond comprises:
 forming the metal bond that couples the metal foil attached to a carrier medium to the first solar cell, wherein the metal foil is pre-patterned; and 
 after forming the metal bond, removing the carrier medium. 
 
     
     
       8. The method of  claim 2 , wherein bonding the substantially transparent layer, the first encapsulant, the first solar cell, the metal foil, the backing material and the back layer to form the photovoltaic laminate includes performing a method selected from the group consisting of curing, thermal curing, curing with Ultra Violet light and performing a standard lamination process to form a photovoltaic laminate. 
     
     
       9. A method for metallization for a photovoltaic laminate, the photovoltaic laminate having a front side which faces the sun during normal operation and a back side opposite the front side, the method comprising:
 placing a first encapsulant on a substantially transparent layer that comprises the front side of the photovoltaic laminate; 
 placing a first solar cell on the first encapsulant; 
 placing a metal foil on the first solar cell, wherein a first surface of the metal foil uniformly contacts a back side of the first solar cell; 
 forming a metal bond that couples the metal foil to the first solar cell; 
 after forming the metal bond that couples the metal foil to the first solar cell, placing a backing material directly on a second surface of the metal foil; 
 forming a back layer on the backing material layer; and 
 curing the substantially transparent layer, the first encapsulant, the first solar cell, the metal foil, the backing material and the back layer to form a photovoltaic laminate.